Method of anchoring pullwire directly articulatable region in catheter

Abstract

A catheter comprises a flexible polymer catheter body including a proximal shaft section and a distal working section, a wire support structure embedded within the distal working section of the catheter body, a proximal adapter mounted to the proximal shaft section of the catheter body, and a wire disposed within the catheter body. The wire has a proximal end and a distal end. The proximal end of the wire being operably connected to the proximal adapter, and the distal end of the wire is anchored to the wire support structure.

What is claimed is: 
     
         1 . A catheter, comprising:
 a flexible polymer catheter body including a proximal shaft section and a distal working section;   a wire support structure embedded within the distal working section of the catheter body;   a proximal adapter mounted to the proximal shaft section of the catheter body; and   a wire disposed within the catheter body, the wire having a proximal end operably connected to the proximal adapter, and a distal end anchored to the wire support structure.   
     
     
         2 . The catheter of  claim 1 , wherein the wire support structure is a braided tubular structure. 
     
     
         3 . The catheter of  claim 1 , wherein the wire support structure is a coiled structure. 
     
     
         4 . The catheter of  claim 1 , wherein the wire support structure comprises a plurality of tubular layers, wherein the distal end of the wire is anchored between the tubular layers of the wire support structure. 
     
     
         5 . The catheter of  claim 1 , further comprising a lumen disposed within the catheter body, wherein the wire is a pullwire extending through the lumen, the distal working section of the catheter body is a distal articulatable section, and the proximal adapter is a proximal steerable interface that is manipulatable to selectively tension the pullwire to bend the distal articulating section. 
     
     
         6 . The catheter of  claim 1 , further comprising an electrode mounted to the distal working section of the catheter body, wherein the wire is an electrical wire, the distal end of which is electrically coupled to the electrode. 
     
     
         7 . The catheter of  claim 1 , wherein the cross-sectional shape of the catheter body is either circular or rectangular. 
     
     
         8 . The catheter of  claim 1 , further comprising a lumen extending through the catheter body. 
     
     
         9 . A method of constructing a catheter, comprising:
 disposing a wire support structure over an inner polymer tube;   disposing at least one outer polymer tube over the wire support structure and wire;   applying heat to the melt the at least one outer polymer tube, thereby flowing the at least one melted outer polymer tube into the wire support structure;   allowing the at least one melted outer polymer tube to solidify, thereby integrating the wire support structure, inner polymer tube, and at least one solidified outer polymer tube together into a catheter body;   disposing a wire through the catheter body; and   anchoring a distal end of the wire to the wire support structure at a distal end of the catheter body.   
     
     
         10 . The method of  claim 9 , wherein the wire support structure is disposed on the inner polymer tube by braiding filament onto the inner polymer tube. 
     
     
         11 . The method of  claim 9 , wherein the wire support structure comprises a plurality of tubular layers, wherein the distal end of the wire is anchored between the tubular layers of the wire support structure. 
     
     
         12 . The method of  claim 9 , further comprising:
 mounting a proximal adapter to a proximal end of the catheter body; and   operatively coupling a proximal end of the wire to the proximal adapter.   
     
     
         13 . The method of  claim 9 , further comprising disposing a barrier over the wire support structure prior to melting the at least one outer tube, wherein the melting temperature of the barrier is greater than the temperature of the heat applied to the at least one outer polymer tube, and removing the barrier from the catheter body subsequent to allowing the at least one melted outer tube to solidify, thereby exposing a portion of the wire support structure, wherein the distal end of the wire is anchored to the exposed portion of the wire support structure. 
     
     
         14 . The method of  claim 13 , wherein the barrier is a tubular barrier, and the exposed portion of the wire support structure is cylindrical. 
     
     
         15 . The method of  claim 13 , further comprising:
 disposing another outer polymer tube over the exposed cylindrical portion of the wire support structure;   melting the other polymer tube, thereby flowing the other outer polymer tube into the exposed cylindrical portion of the wire support structure; and   allowing the other melted outer polymer tube to solidify.   
     
     
         16 . The method of  claim 9 , further comprising forming a lumen within the catheter body, wherein the wire is a pullwire extending through the lumen, and the proximal adapter is a proximal steerable interface. 
     
     
         17 . The method of  claim 16 ,
 wherein forming a lumen within the catheter body comprises disposing a process mandrel over the inner polymer tube prior to melting the at least one outer tube, and removing the process mandrel from the catheter body subsequent to allowing the at least one melted outer tube to solidify; and   wherein disposing the wire through the catheter body comprises threading the wire through the lumen.   
     
     
         18 . The method of  claim 9 , wherein the wire is an electrical wire, and the method further comprises forming an electrode to the catheter body in electrical communication with the wire. 
     
     
         19 . The method of  claim 18 , wherein forming the electrode on the catheter body comprises disposing a barrier over the wire support structure prior to melting the at least one outer tube, removing the barrier from the catheter body subsequent to allowing the at least one melted outer tube to solidify, thereby exposing a portion of the wire support structure, and disposing the electrode on the exposed portion of the wire support structure. 
     
     
         20 . The method of  claim 9 , wherein anchoring the distal end of the wire to the wire support structure comprising soldering, welding, brazing, or gluing the distal end of the wire to the wire support structure. 
     
     
         21 . The method of  claim 9 , wherein the inner polymer tube has a lumen extending therethrough.